Suspension system and structure for securing border ceiling panels

ABSTRACT

An apparatus and system to secure a panel to suspended ceiling system which includes a plurality of suspension elements. The apparatus is a border structure that enables attachment of the panel to the suspension element. The border structure includes a plurality of horizontal surface members and a plurality of vertical sections, with a first horizontal surface member being inserted into a hanger secured to the suspension element, and with a second horizontal surface member supporting an end of a panel. At least one vertical section joins the plurality of horizontal surface members. A spring hold down clip secures the panel from unintended displacement during a seismic event.

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/451,440, filed Mar. 3, 2003.

FIELD OF THE INVENTION

[0002] The present invention relates generally to suspension systems,and more particularly, to a ceiling border structure which can beutilized in an suspended ceiling system. The border structure, alsoreferred to herein as a border member, is secured to suspension channelsin the ceiling system and not to a wall or partition. As a result, theborder member can be utilized in island/floating ceiling systems. It isalso desirable to utilize the border member of the invention in ceilingsystems used in locations that experience low to severe seismicactivity.

BACKGROUND

[0003] Suspended ceiling systems, including exposed metal grid systemsfor lay in panels and systems utilizing metal hook-on type panels, areextensively used in private and commercial buildings. Such ceilingsystems are suspended from the building structure and provide asubstantially uninterrupted planar ceiling appearance. Lightingfixtures, air handling vents and the like are often incorporated atvarious locations in the system.

[0004] Conventional suspended ceiling systems which utilize metal panelsoften include supporting grid elements structured to grip the upstandingedges of the metal panels. Ceiling systems utilizing metal panels haveapplication to buildings that have large ceiling areas or high accessareas. These systems are most frequently used in corridors, lobbies,entryways, and hospitality and retail spaces. The metal panels come inwidths of varying sizes, are completely accessible and fully conceal thesuspension system. The panels provide downward accessibility, requiringminimum plenum clearance.

[0005] In geographical regions subject to earthquakes, buildings aredesigned with lateral force resisting systems, i.e. seismic systems, toresist the effects of earthquake forces. Seismic systems make a buildingstiffer against horizontal forces, thus minimizing the amount ofrelative lateral movement and resultant damage. Although the buildingsmay be designed structurally to provide seismic resistance to lateralforces, the ceiling panels suspended adjacent the trim or border of theceiling system remain very susceptible to displacement under severeenvironmental conditions. Thus, the connection of the wall or partitionto the ceiling system, ceiling system members and their connections mustbe designed to support the reaction force of the wall or partition fromprescribed loads applied perpendicular to the wall or partition during aseismic event.

[0006]FIGS. 1 and 2 illustrate a suspended asymmetric ceiling systemwhich is typically utilized in areas subject to seismic disturbances.The panels positioned adjacent the wall, herein referred to as borderpanels, are supported by metal L-beam members, often referred to as wallangles, which are fastened to the wall with nails or screws. In thisknown configuration, the status of the border panels is partiallydependent on the status of the wall or partition. By way of example, ifthe wall to which the wall angle is secured were to be collapse, theborder panels supported by the wall angle would fall, potentiallyinjuring people in the room below. Accordingly, there is a need for aceiling system which secures border panels from unintended displacement.It is also desirable to allow for the border panels to be accessible asusual for installation and de-installation.

[0007] Also, island, or floating, ceiling systems, in which thetermination of the ceiling plane stands proud of the wall, are inincreasing demand as such systems provide an architect withsubstantially unlimited aesthetic variations in a ceiling system.

SUMMARY

[0008] The present invention provides a suspended ceiling system inwhich the border panels are secured to the suspension elements of asuspended asymmetric ceiling system. The ceiling system includes aplurality of suspension elements, a plurality of grid elements, aplurality of hangers and a plurality of border structures. Each hangerhas a slot for attaching either a grid element or a border structure toa suspension element.

[0009] Each border structure has a plurality of horizontal surfacemembers and a plurality of intervening vertical surface members. A firsthorizontal surface member can be inserted into a hanger slot forattaching the border structure to a suspension element. A secondhorizontal surface member supports a border panel. As a result, theborder panel is attached to the suspended ceiling system and unintendeddisplacement of the border panels is avoided should the wall bedisplaced.

[0010] Various other advantages stem from the ceiling system and borderstructure of the invention. One advantage is that the system is simplerand economical to use. For example, the system requires only one borderstructure extrusion as there is no need to design and manufacture customsizes with custom miter cuts. The absence of the need for multipleextrusions results in savings in manufacturing and makes installationand replacement less complicated. In addition, as the border element isextruded and is therefore softer, it is easier to field cut. By beingeasier to field cut, the installer can feel more comfortable makingvarious angle cuts on the border structure.

[0011] Further, the border element of the invention can be used at bothwall and bulkhead locations. As the border element can be used inmultiple locations, and as custom sizing is no longer required, it ispractical to stock the border member. The ability to stock the bordermember results in a large reduction in manufacturing lead times, whichcan be utilized as a marketing tool. In addition, the border elementeliminates the need to manufacture custom size panels to fit thearchitecture and standard suspension components placed on walls.

[0012] The invention possesses many other advantages, and has otherpurposes which may be made more clearly apparent from consideration ofthe example embodiments. The example embodiments are shown in theaccompanying drawings and form part of the specification. The exampleembodiments will now be described in detail for the purpose ofillustrating the general principles of the invention, but it is to beunderstood that the description of the example embodiments should not beconsidered limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 illustrates a perspective view of a section of a suspendedceiling system utilizing metal hook-on panels according to the priorart.

[0014]FIG. 2 illustrates a side view of the suspended ceiling system ofFIG. 1 wherein a cut panel is supported at a wall location according tothe prior art.

[0015]FIG. 3 illustrates a perspective view of a border structure inaccordance with an exemplary embodiment of the invention.

[0016]FIG. 4 illustrates a side view of the border structure of FIG. 3.

[0017]FIG. 5 illustrates a side view of a portion of a suspended ceilingsystem utilizing the border structure of FIG. 3.

[0018]FIG. 6 illustrates a perspective view of a portion of a suspendedceiling system utilizing the border structure of FIG. 3.

[0019]FIG. 7 illustrates a partial perspective view of a borderstructure in accordance with a second exemplary embodiment of theinvention.

[0020]FIG. 8 illustrates a side view of a portion of a ceiling systemutilizing the border structure of FIG. 7.

DETAILED DESCRIPTION OF THE DRAWINGS

[0021] The following description of the invention is provided as anenabling teaching of the invention in its best, currently knownembodiment. Those skilled in the relevant art will recognize that manychanges can be made to the embodiments described while still obtainingthe beneficial results of the present invention. It will also beapparent that some of the desired benefits of the present invention canbe obtained by selecting some of the features of the present inventionwithout utilizing other features. Accordingly, those who work in the artwill recognize that many modifications and adaptations to the presentinvention are possible and may even be desirable in certaincircumstances and are a part of the present invention. Thus, thefollowing description is provided as illustrative of the principles ofthe present invention and not in limitation thereof, since the scope ofthe present invention is defined by the claims.

[0022]FIG. 1 displays a known hook-on metal panel 150, such as theRH-200 metal panel available from Armstrong World Industries, installedin a known asymmetric J-bar suspension system. A typical asymmetricsuspension system includes grid elements, such as U-profiles, andsuspension elements, such as J-bars or H-bars. FIG. 1 illustrates asuspension system having a U-profile 100 being supported by 12-gaugehanger wire 130, spaced 4 feet on center. The system also has J-bar gridelements 110 which are attached to the U-profile 100 at every module,wherein a module is dictated by the length of a panel 150. The J-bar 110is connected to the U-profile 100 with a hanger 120 having a slot inwhich the top straight leg 122 of the J-bar 110 is installed. A plug-inclip 140 can be used to secure the J-bar hanger 120 to the U-profile 100at a desired module. The plug-in clip 140 can be formed from a singlepiece of resilient spring metal folded upon itself to define a base andfirst and second arms extending from the base in spaced relation. Afastener 124 (shown in FIG. 2), such as a bolt-type fastener, can beused to secure the straight leg 122 of the J-bar 110 in the hanger slot.FIGS. 1 and 2 also show how the edges 152, 154 of adjacent panels 150are positioned over the J-bar 110. A foam gasket 160 may be used toseparate and provide isolation between adjacent panels.

[0023]FIG. 2 shows a cut border panel 250 supported at a wall locationaccording to the prior art. At the uncut end, the border panel 250 ishung from a J-bar 110. The cut end of the border panel 250 is typicallypositioned no closer than 0.5 inches from the bulkhead 200 and is helddown by clip 230 which is also fixedly attached to the wall 300 by screw350. The border panel 250 is not attached to the U-profile at the cutend. Although the end of the panel adjacent the border structure isoften referred to herein as the cut end of the panel, it should be notedthat it may not be necessary to cut this end if it is not requiredduring installation.

[0024]FIGS. 3 and 4 display a border structure according to the presentinvention which is attachable to a suspension element, such as aU-profile, and is capable of supporting a border panel. The borderstructure 420 includes a plurality of horizontal surface members and aplurality of intervening vertical sections which join the plurality ofhorizontal surface members. The border structure 420 includes first andsecond horizontal surface members, 424 and 428 respectively. As shown inFIG. 5, the first horizontal surface member 424 can be inserted in theslot of the J-bar hanger 120 to secure the border structure 420 to theU-profile 100. As shown in FIG. 6, the border structure can be rotated180° so that the second horizontal surface member 428 can be insertedand secured in the slot of the J-bar hanger 120.

[0025] The border structure 420 also has first and second verticalsections, 425 and 427 respectively, and a third horizontal surfacemember 426 positioned between the first and second horizontal surfacemembers 424, 428. The third horizontal surface member 426 adjoins thefirst and second vertical sections 425, 427. A first pair of hold downclip flanges, 430, 431 extend horizontally from the first verticalsection 425. A second pair of hold down clip flanges, 432, 433, extendhorizontally from the second vertical surface member 427. The first andsecond pairs of hold down clip flanges run the entire longitudinallength of the border element 420 and provide respective grooves 441 forplacement of standard spring hold down clips 440. Having a groove 441which runs along the entire length of the border member 420 allows aninstaller to cut the border member 420 at any location along its length.

[0026]FIG. 5 illustrates a spring hold down clip 440 positioned ingroove 441 positioned proximate the horizontal surface member 428. Asfurther shown in FIG. 4, flanges 431 and 433 may include a rounded edgeto lock the spring hold down clip 440 in the groove 441 provided by thepairs of hold down clip flanges. The spring hold down clip 440 istensioned and resilient when locked in groove 441. As a result, thespring hold down clip 440 is capable of securing the cut end of a borderpanel so that the border panel is not displaced from the borderstructure during a seismic event.

[0027] Further, a boss 434 extends vertically from flange 431 and isopposite from a second boss 436 which extends vertically from the thirdhorizontal surface member 426. These bosses 434, 436 provide a channelfor a simple connector 530 (shown in FIG. 8), such as a splice plate.The splice plate, which is typically composed of galvanized sheet steel,frictionally engages abutting border elements 420, even at cornerlocations. The channel, which runs the entire length of the bordermember 420, allows an installer to cut the border member 420 at anylocation and at any angle along the length of the border element 420. Asa result, the need to design border elements having custom lengths andcustom miter cuts is avoided.

[0028] The border structures can be formed by the extrusion of analuminum sheet or a metal sheet. The border structure can also beroll-formed from a metal sheet.

[0029] As shown in FIGS. 5 and 6, the border element 420 can be attachedto the J-bar hanger 120 by positioning either the first horizontalsurface member 424 or second horizontal surface member 428 of the borderelement 420 in the slot of J-bar hanger 120. When the first horizontalsurface member 424 is inserted in the slot of the hanger 120, as shownin FIG. 5, the second horizontal surface member 428, the second verticalsection 427 and third horizontal surface member 426 provide a stepmolding visual aspect. When the second horizontal surface member 428 isinserted in the slot of the hanger 120, as shown in FIG. 6, the firsthorizontal surface member 424 and the first vertical section 425 providea standard wall molding visual aspect.

[0030] A fastener 160 secures either the first or the second horizontalsurface member in the slot of the J-bar hanger 120. In turn, a plug-inclip 140 secures the J-bar hanger 120 to the U-profile 100. The borderpanel 250 is placed inside the border element 420 where it is supportedby either the first or second horizontal surface members, depending onwhich of the first or second surface members is not inserted in the slotof the J-bar hanger 120. Thus, the border panel 250 is secured to theU-profile and, as a result, the status of the border panel is dependenton the status of the ceiling system, not the wall or partition.

[0031]FIGS. 7 and 8 illustrate a second example embodiment of the borderelement. In this configuration, the border structure 500 includes avertical section 510 and first surface member 512 extending horizontallyfrom a first edge of the vertical section 510. The border element 500further includes a second surface member 514 which extends horizontallyfrom the vertical section 510 and is spaced apart from the firsthorizontal surface member 512. A pair of hold down clip flanges, 520,522 also extend horizontally from the vertical section 510 adjacent thefirst horizontal surface member 512. The hold down clip flanges 520, 522run the entire longitudinal length of the border element 500 and providea groove 521 for placement of a standard spring hold down clip 440.Flange 522 may include a rounded edge distal the vertical section 510 tolock the spring hold down clip 440 in the groove 521. The spring holddown clip 440 secures the cut end of a border panel so that the borderpanel is not displaced from the border structure during a seismic event.

[0032] The border element 500 further includes a pair of splice platesupport flanges 524, 526 extending horizontally from the verticalsection 510 and positioned between hold down clip flange 522 and thesecond horizontal surface member 514. A first boss 527 extendsvertically from splice plate support flange 524 and is opposite a secondboss 528 extending vertically from splice plate support flange 526.These bosses 527, 528 provide a splice channel for splice plate support.

[0033] For additional splice plate support, additional splice platechannels are provided. As shown in FIG. 7, the second horizontal surfacemember 514 has a first portion 532 extending horizontally from thevertical section S10 and a second portion 534 extending horizontally ina plane offset from the first portion 532. The second portion 534 isconnected to and spaced vertically apart from the first portion 532 byan intervening substantially vertical portion 533. The border structure500 can further include a third surface member 516 which extendshorizontally from a second edge of the vertical section 510, oppositethe first edge. A boss 536 extends vertically from the third horizontalsurface member 516 and is located opposite the substantially verticalportion 533 of the second horizontal surface member 514. The boss 536 ofthe third horizontal surface member 516 and the substantially verticalportion 533 provide a splice channel.

[0034] As shown in FIG. 8, the border element 500 can be attached to theJ-bar hanger 120 by positioning the second portion 534 of the secondhorizontal surface member 514 in the slot of J-bar hanger 120. When thesecond horizontal surface member 514 is inserted in the slot of thehanger 120, the first horizontal surface member 512, which is adjacentthe room below, supports a border panel and, along with the verticalsection 510, provides a standard wall molding visual aspect. Thisexample embodiment of the border element 500 can also be utilized at alocation in the interior of a room, such as in an island ceiling system.The border element 500 is preferably used in island ceiling systems asthe border element 500 is able to cover the basic framework of thesuspension system adjacent the border element 500.

[0035] The corresponding structures, materials, acts, and equivalents ofall means plus function elements in the claims below are intended toinclude any structure, material, or acts for performing the function incombination with other claim elements as specifically claimed. Thoseskilled in the art will appreciate that many modifications to theexemplary embodiments of the present invention are possible withoutdeparting from the spirit and scope of the present invention.

We claim:
 1. An apparatus for securing a panel in a suspended ceilingsystem having a plurality of suspension elements, the apparatuscomprising: a border structure for attachment of the panel to thesuspension element, the border structure including a plurality ofhorizontal and vertical surface members, wherein a horizontal surfacemember is inserted into a hanger secured to a suspension element, andwherein another horizontal surface member supports a panel.
 2. Theapparatus of claim 1 further comprising a plug-in clip to secure thehanger to the suspension element.
 3. The apparatus of claim 1 furthercomprising a spring clip, the spring clip keeping a cut end of a borderpanel from displacement from the border structure during a seismicevent.
 4. The apparatus of claim 1, wherein the border panel has a cutend supported by the border structure and an uncut end supported by agrid element which is attached to a suspension element.
 5. The apparatusof claim 4, wherein the grid element is attached to the suspensionelement by a hanger.
 6. The apparatus of claim 4, wherein the gridelement is a J-bar structure.
 7. The apparatus of claim 1, wherein thesuspension element is a U-profile structure.
 8. The apparatus of claim1, wherein the border structure is fabricated from a metal sheet.
 9. Theapparatus of claim 1, wherein the border structure is formed by anextrusion of metal.
 10. The apparatus of claim 1, wherein the borderstructure is roll-formed from a metal sheet.
 11. A system for securing aborder panels comprising: a plurality of suspension elements; aplurality of border structures, each border structure being secured toat least one of the plurality of suspension elements and supporting anend of a border panel; a plurality of grid elements, each grid elementbeing secured to a suspension element and supporting an end of a borderpanel; a plurality of hangers, each hanger having a slot for attachingthe plurality of a border elements and the plurality of grid elements tothe suspension elements.
 12. The system of claim 11, wherein each borderstructure includes a plurality of horizontal and vertical surfacemembers, a first horizontal surface member being inserted into a hangerand secured to the suspension element and a second horizontal surfacemember supporting the end of a panel inserted into the border structurebetween the first and second horizontal surface members.
 13. The systemof claim 11, further comprising a plurality of plug-in clips whichsecure the plurality of hangers to the plurality of suspension elements.14. The system of claim 11, wherein the plurality of suspension elementsare U-profile structures.
 15. The system of claim 11, wherein theplurality of grid elements are J-bar structures.
 16. The system of claim11, wherein the plurality of border structures are formed by metalextrusions.
 17. The system of claim 11, wherein the plurality of borderstructures are roll-formed from metal sheets.
 18. The system of claim11, wherein each border structure further comprises a spring hold downclip to secure a cut end of the panel from displacement from the borderstructure during a seismic event.
 19. The system of claim 11, furthercomprising a plurality of panels, each panel having a cut end beingsupported by a border structure and an uncut end being supported by-agrid element.
 20. A border structure comprising: a first horizontalsurface member for supporting an end portion of a panel; an secondhorizontal surface member; a third horizontal surface member positionedbetween the first and second horizontal surface members; a firstvertical section adjoining the first horizontal surface member and thethird horizontal surface member to provide a step molding; and a secondvertical section adjoining the second horizontal surface member and thethird horizontal to provide a perimeter molding.
 21. The borderstructure of claim 20, wherein each of the first and second verticalsections include a pair of hold down clip flanges which extendhorizontally from the first and second vertical sections.
 22. The borderstructure of claim 20, wherein the end portion of the panel is cutbefore placement on the first horizontal surface member.
 23. The borderstructure of claim 20, wherein the border structure is formed by a metalextrusion.
 24. The border structure of claim 20, wherein the borderstructure is fabricated from a metal sheet.
 25. A border structurecomprising: a vertical section having first and second edges; a firstsurface member extending horizontally from the first edge; and a secondsurface member extending horizontally from the vertical section andbeing spaced apart from the first surface member; whereby the borderstructure covers the framework of an adjacent suspension system.
 26. Theborder structure of claim 25, wherein the second horizontal surfacemember has a first portion extending horizontally from the verticalsection and a second portion extending horizontally in a plane offsetfrom the first portion, the second portion being connected to and spacedvertically apart from the first portion by an intervening substantiallyvertical portion.
 27. The border structure of claim 25, furthercomprising a third surface member extending horizontally from the secondedge of the vertical section.